Effect of Tool Shape on Surface Finish of Components Formed Through Incremental Sheet Forming Process

2015 ◽  
Author(s):  
Pavan Kumar ◽  
Satwik Priyadarshi ◽  
J. J. Roy ◽  
M. K. Samal ◽  
P. K. Jain ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Experimental Investigations ◽  
Tool Geometry ◽  
Forming Process ◽  
Tool Geometries ◽  
Tool Shape ◽  
Experimental Approaches

This work explores the effect of tool geometry on surface finish in incremental sheet forming (ISF) process. In the present work, two different tool geometries i.e. hemispherical shaped tool and ellipsoidal shaped tool are considered. Area at tool-sheet contact and scallop height were calculated for both the tool geometries. To assess the effect of tool geometry on the surface finish of the formed components, both analytical and experimental approaches have been used. A test geometry having the shape of frustum of pyramid was considered for the proposed investigation and four surface roughness parameters i.e. arithmetic mean surface roughness (Ra), root mean square surface roughness (Rq), maximum peak-to-valley height (Rt) and average peak-to-valley height (Rz) have been selected as response parameters. Based on the analytical model and experimental investigations, both qualitative and quantitative comparisons had been made among the effects of hemispherical and ellipsoidal tool geometries on surface finish. The investigation deduces that better surface finish of the formed component can be achieved by using ellipsoidal shaped tool rather than the hemispherical shaped tool.

Investigating the Effect of Process Parameters in Incremental Sheet Forming Process

2021 ◽  
pp. 24-36
Author(s):  
Manish Oraon ◽  
Manish Kumar Roy ◽  
Vinay Sharma
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Forming Process ◽  
Batch Production ◽  
Force Microscopy ◽  
Atomic Force ◽  
Roughness Analysis ◽  
Step Down

Incremental sheet forming (ISF) is an emerging technique of sheet metal working that comes into the picture in the last two decades. The ISF involved the forming of shapes without using the dedicated dies. ISF is suitable for customized products, rapid prototyping, and low batch production. The study aims to investigate the effect of process parameters on the surface roughness. The experiments are conducted on aluminum AA3003-O grade with six parameters, and the trials are performed according to the design of experiment (DOE). The atomic force microscopy (AFM) technique is used for measuring the surface roughness. Analysis of variance (ANOVA) is used for analyzing the effect of process parameters in ISF. The result shows that the step-down size, feed rate of the tool, and wall angle are significant process parameter and their contributions for ISF are 85.86%, 1.12%, and 12.29%, respectively.

The influence of the lubrication in the surface roughness in the incremental sheet forming process

2015 ◽  
Author(s):  
Daniel de Castro Maciel ◽  
Gilmar Cordeiro da Silva ◽  
Luís Henrique Andrade Maia ◽  
Lúcio Flávio Santos Patrício ◽  
Jánes Landre Júnior
Keyword(s):  
Surface Roughness ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Forming Process

scholarly journals A Comparative Investigation of Conventional and Hammering-Assisted Incremental Sheet Forming Processes for AA1050 H14 Sheets

Metals ◽  
2021 ◽  
Vol 11 (11) ◽  
pp. 1862
Author(s):  
Harshal Y. Shahare ◽  
Abhay Kumar Dubey ◽  
Pavan Kumar ◽  
Hailiang Yu ◽  
Alexander Pesin ◽  
...  
Keyword(s):  
Surface Finish ◽  
Shot Peening ◽  
Numerical Models ◽  
Local Deformation ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Grain Structure ◽  
Experimental Investigations ◽  
Wall Angle ◽  
Truncated Cone

Incremental Sheet Forming (ISF) is emerging as one of the popular dieless forming processes for the small-sized batch production of sheet metal components. However, the parts formed by the ISF process suffer from poor surface finish, geometric inaccuracy, and non-uniform thinning, which leads to poor part characteristics. Hammering, on the other hand, plays an important role in relieving residual stresses, and thus enhances the material properties through a change in grain structure. A few studies based on shot peening, one of the types of hammering operation, revealed that shot peening can produce nanostructure surfaces with different characteristics. This paper introduces a novel process, named the Incremental Sheet Hammering (ISH) process, i.e., integration of incremental sheet forming (ISF) process and hammering to improve the efficacy of the ISF process. Controlled hammering in the ISF process causes an alternating motion at the tool-sheet interface in the local deformation zone. This motion leads to enhanced material flow and subsequent improvement in the surface finish. Typical toolpath strategies are incorporated to impart the tool movement. The mechanics of the process is further explored through explicit-dynamic numerical models and experimental investigations on 1 mm thick AA1050 sheets. The varying wall angle truncated cone (VWATC) and constant wall angle truncated cone (CWATC) test geometries are identified to compare the ISF and ISH processes. The results indicate that the formability is improved in terms of wall angle, forming depth and forming limits. Further, ISF and ISH processes are compared based on the numerical and experimental results. The indicative statistical analysis is performed which shows that the ISH process would lead to an overall 10.99% improvement in the quality of the parts primarily in the surface finish and forming forces.

A Mixed Toolpath Strategy for Improved Geometric Accuracy and Higher Throughput in Double-Sided Incremental Forming

2014 ◽  
Author(s):  
Rui Xu ◽  
Huaqing Ren ◽  
Zixuan Zhang ◽  
Rajiv Malhotra ◽  
Jian Cao
Keyword(s):  
Incremental Forming ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Geometric Accuracy ◽  
Recent Past ◽  
Forming Process ◽  
Process Flexibility ◽  
Formed Part ◽  
Future Work

Incremental sheet forming has attracted considerable attention in the recent past due to advantages that include high process flexibility and higher formability as compared to conventional forming processes. However, attaining required geometric accuracy of the formed part is one of the major issues plaguing this process. The Double-Sided Incremental Forming process has emerged as a potential process variant which can preserve the process flexibility while maintaining required geometric accuracy. This paper investigates a mixed toolpath for Double-Sided Incremental Forming which is able to simultaneously achieve good geometric accuracy and higher throughput than is currently possible. The geometries of parts formed using the mixed toolpath strategy are compared to the desired geometry. Furthermore, an examination of the forming forces is used to uncover the reasons for experimentally observed trends. Future work in this area is also discussed.

An approach to eliminate stepped features in multistage incremental sheet forming process: Experimental and FEA analysis

2017 ◽  
Vol 31 (2) ◽  
pp. 599-604 ◽  
Author(s):  
Harish Kumar Nirala ◽  
Prashant K. Jain ◽  
J. J. Roy ◽  
M. K. Samal ◽  
Puneet Tandon
Keyword(s):  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Forming Process ◽  
Fea Analysis
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